External Parts

4-1

4. External Parts

Service Information

NOTE

This section describes external parts removal/installation.

Do not apply unreasonable force when disassembling covers, to prevent possible damage.

A muffler is hot. Do not service it immediately after the engine is stopped.

Service Information 4-1

Maintenance Procedure 4-2

External Parts Removal/Installation 4-3

Muffler 4-9

Front Fender 4-10

External Parts

4-2

This chart shows arrows connected in the order of disassembling covers.

Front cover

Inner box

Front side cover

Floor side cover

Maintenance cover

Center cover

Rear under cover

Rear handle cover

Body cover

Floor panel

Front handle coverLuggage box

Rear carrier

Tail combination-light

Rear upper cover

Maintenance Procedure

Names of frame covers

External Parts

4-3

Front Cover removal/InstallationLoosen the 2 upper screws.

Loosen the 2 lower screws.

Pull upward and remove the front cover.

Install in the reverse order of removal.

Front Side Cover Removal/InstallationRemove the front fender. ( 4-10)

Remove the front wheel. ( 12-5)

Remove the 2 front lower flange bolts and the 2 upper screws.

Remove the 2 inner box setting screws.

Remove the front side cover.

Install in the reverse order of removal.

Screw

Front cover

Screw

Inner box

Front side coverBolt

Screw

Screw

External Parts

4-4

Inner BoxLoosen the 2 bolts installed on the bag holder.

Remove the bag holder.

Open the inner box lid.

Remove the 1 cap nut.

Remove the 2 flange bolt installed on the floor

panel.

Remove the 6 front side cover screws.

Remove turn the main key cover slightly to

unlock, and remove the main key cover.

Remove the charge socket from the inner box.

Remove the inner box.

Install in the reverse order of removal.

Center CoverLoosen the 4 setting screws assembled to the

body cover.

Remove each of the setting screws assembled to

the floor panel.

Band inwards, and remove the center cover.

Install in the reverse order of removal.

Screw

Front inner box

Nut

Bolt

Charge socket

Bag holder

Radiator

Screw

Center cover

Screw

Flug maintenance cover

4-5

External Parts

Side CoverRemove the floor mat.

Loosen the 2 screws on the side of the

R/L side covers.

Loosen 1 each of the R/L screws

assembled to the floor panel.

Loosen 3 each of the R/L body cover

clips assembled to the floor panel.

Remove R/L side covers.

Install in the reverse order of removal.

Luggage BoxUnlock the system with the main key, and open

the seat.

Loosen the 4 cap nuts.

Remove the fuel tank cap.

NOTE

Remove the luggage box.

Install in the reverse order of removal.

Remove the wiring of trunk lamp.

Side cover

Side stand

switch

Seat

Fuel tank cap

Luggage

box

NutScrew

Trunk lamp

Hinge

pin

Bolt

Bolt

Assemble the fuel tank cap after removing the

luggage box.

External Parts

4-6

Rear CarrierLoosen 1 each of the R/L flange bolt set on the

body cover side.

Loosen the 2 flange bolts set on top of the body

cover.

Remove the rear carrier.

Install in the reverse order of removal.

Body Cover/Rear CoverRemove the rear carrier. ( 4-6)

Remove the luggage box. ( 4-5)

Remove the center cover. ( 4-4)

Loosen 2 each of the R/L body cover

grill screws set with the floor panel.

Loosen 1 each of the R/L body cover

clips assembled to the rear fender.

Loosen 1 each of the R/L flange bolts set

on the frame body.

Loosen 2 rear under cover setting screws,

and remove the rear under cover.

Remove the R/L frame body cover.

Loosen the 2 rear upper cover setting

screws.

Install in the reverse order of removal.

Screw

Body cover clip

Rear upper cover

Frame body

cover

fuel fiter

puel pump

Rear carrier

Screw

Tail Combination-LightRemove the following parts.

- Luggage box. ( 4-5)

- Luggage carrier. ( 4-6)

- Body cover. ( 4-6)

- Rear under cover. ( 4-6)

Loosen the 2 bolts assembled

to the frame rear part.

Loosen the 2 R/L side setting

bolts.

Remove the tail combination-

light wiring.

Remove the tail combination-

light

Install in the reverse order of

removal.

4-7

External Parts

Floor Panel/Battery CoverRemove the center cover. ( 4-4)

Loosen 2 each of the R/L pillion step

cover setting screws of the floor mat, and

remove the floor mat.

Loosen the 2 battery cover setting

screws, and remove the battery cover.

Withdraw the battery wiring, and

remove the battery.

Remove the air cleaner duct.

Loosen the 4 setting bolts.

Remove the side cover. ( 4-5)

Remove the 4 center cover setting

screws.

Remove the floor panel.

Install in the reverse order of removal.

Floor

mat

Screw

Floor panel

Bolt

Bolt

Bolt

Rear under

cover

Screw

Bolt

Battery cover

cover

External Parts

4-8

Handle Cover

Front Handle Cover

Loosen the 4 rear handle cover setting screws.

(1 each on R/L side, and 2 each on meter side)

Loosen 1 front handle cover setting screw.

Remove 1 R/L handle side cover lower screw,

and 1 each of the special upper side screws.

Pull the front handle cover forward, and remove

the wiring.

Remove the front handle cover.

Install in the reverse order of removal.

Rear Handle Cover

Loosen the 3 screws assembled to the handle bar.

Loosen the 3 screws assembled to the meter.

Remove the R/L side switch wiring.

Remove the rear handle cover.

Install in the reverse order of removal.

Rear view mirror Bolt

Screw

Screw

Front handle cover

Handle side

cover

Meter

Rear handle

cover

Rear master

cylinder

Speedometer cable

Screw

4-9

Muffler

Removal

Loosen the 3 flange nuts securing the EX. pipe comp.

Loosen the rear brake hose setting bolt.

Loosen the flange bolt securing the rear wheel

mud guard.

Loosen the 2 flange bolts securing the R. crankcase.

Remove the EX. muffler comp.

WARNING

EX. Pipe removal

Remove the plug maintenance cover.

Loosen the 2 flange bolts securing the cylinder

comp.

Remove the EX. pipe by drawing it to the ground

direction.

Installation

Install the 2 flange bolts after securing the EX.

pipe with the stud bolt of the cylinder comp.

Install the gasket on the EX. muffler, connect the

EX. pipe and install the 2 flange nuts temporarily.

Install the 2 flange bolts on the R.crankcase

temporarily.

Tighten the 3 flange nuts to install the EX. muffler

and EX. pipe.

Install the flange bolt on the rear wheel mud guard.

Tighten the muffler securing 2 flange bolts to

install the R. crankcase.

Tighten torque of the R. crankcase.

Torque: 5.5kg-m(55N.m, 40ft-lb)

Tighten the rear brake hose setting bolt.

WARNING

External Parts

Never perform the maintenance of the muffler

right after stopping the vehicle because the

muffler is extremely hot.

When installing the gasket, replace it with the

new one.

Check to see if there is any evacuation after

installing the muffler.

Flange bolts

Flange bolts

Flange nuts

EX.pipe

EX.pipe

EX.pipe

External Parts

4-10

Front FenderLoosen the flange bolt connecting the front

fender A and B.

Loosen the 2 setting screws of the front fender A,

and remove the front fender A.

Loosen 1 setting screw of the front fender B.

Remove the speedometer cable guide.

Remove the front fender B.

Install in the reverse order of removal.

Fender B

Screw

Screw

Fender A

Bolt

MEMO